Aluminum shotgun shell case, methods of making, and using the same

ABSTRACT

The instant disclosure is directed towards shot shell configurations and methods of making the same.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a non-provisional of and claims priority to U.S. application Ser. No. 62/079,946, entitled “Aluminum Shotgun Shell Case, Methods of Making, and Using the Same” filed on Nov. 14, 2014, which is incorporated by reference in its entirety.

FIELD OF THE INVENTION

Broadly, the instant disclosure is directed towards aluminum shotgun shells. More specifically, the instant disclosure is directed towards aluminum shotgun shells that are formed from an aluminum sheet, methods of making, using, and recycling the same.

BACKGROUND

Existing aluminum shotgun shell cases are impact extruded with an open, crimped end or rolled end. The crimped end is sealed with paper, plastic and/or wax over the crimped, mouth end. Aluminum shotgun shell cases are not widely used as the shells get stuck in the shotguns and the shotgun shell cases are also difficult to feed through semi or pump feed shotguns.

SUMMARY OF THE DISCLOSURE

As used herein, “shot shell” means: (a self-contained) cartridge loaded with a shot or slug, which is designed to be fired from a shotgun. In some embodiment, the shot shell is configured for a 10 gauge, 12 gauge, 16 gauge, 20 gauge, 28 gauge, or 410 gauge shotgun.

As used herein, “case” means: the component of the shot shell that holds the other parts of the shell together. In some embodiments, the case is configured to retain the projectile (shot/slug), the wad, and the charge/propellant (powder) in the shot shell. In some embodiments, the case is configured to cooperate with the base assembly to create a sealed closure (e.g. air tight and/or water tight). In some embodiments, the case is configured from aluminum alloy sheet (e.g. drawn and ironed).

As used herein, “base assembly” means: the lowest component of the part something, especially the part on which it rests or is supported. In some embodiments, the base assembly is the portion of the shot shell that is retained in the head end. In some embodiments, the base assembly is configured to retain the charge (powder) and/or the primer cup. In some embodiments, the base assembly is drawn and ironed from aluminum alloy sheet. In some embodiments, the base assembly is impact extruded (e.g. stamped and formed).

As used herein, “mouth end” (sometimes referred to as the top end) means: the end of the shot shell that is closest to the mouth of the casing or firing end of the rifle (e.g. when in firing position, closest to the open end of the barrel). In some embodiments, the mouth end is configured to release the projectiles (e.g. slug, shot, etc) from the shot shell cartridge case.

As used herein, “head end” means: the end of the shot shell that is closest to the firing pin of the firearm. In some embodiments, the head end includes the end of the shot shell that encloses the base assembly (e.g. contains the primer). In some embodiments, the head end includes the base assembly and rim.

As used herein, “mating edge” means an edge which is configured to mechanically connect with another component. In some embodiments, the base assembly is configured with a mating edge, comprising an extension (e.g. perimetrically surrounding the base assembly) which is configured to cooperate with a corresponding rim of the case (e.g. to provide a sealed closure).

As used herein, “rim” means: the portion of the case which is configured with a perimetrical lip or collar extension from the sidewall of the case, which is configured to cooperate with a corresponding mating edge of the base assembly. In some embodiments, the case is configured with a rim, which is configured to perimetrically surround the case, adjacent to the head end.

As used herein, “score” means: a cut, notch, or scratch on a surface of a component. In some embodiments, a score is created on the surface of substrate (e.g. the mouth end) via mechanical tooling, EDM, and/or laser beam.

As used herein, “score pattern” means: a scoring model or design. In some embodiments, the score pattern is used as a guide during the firing event to promote and/or define parameters of the firing event (e.g. narrow or wide shot dispersal).

As used herein, “cap” means: a lid or cover for an object (i.e. configured to offer protection or enclosure of the object from the surrounding environment). In some embodiments, the cap is configured to fit onto and be retained by an open end of the case (e.g. the mouth end of the case, where the case is configured with an integral/unitary base assembly and case).

In some embodiments, the cap is attached to the mouth end of the case via a roll seam. In some embodiments, the cap is attached to the mouth end of the case via a lock seam. In some embodiments, the cap is attached to the mouth end of the case via an adhesive. In some embodiments, the cap is attached to the mouth end of the case with both a forming operation (e.g. roll seam or lock seam) and an adhesive.

As used herein, “sealant” means: a material that is used for sealing components together (e.g. to make the components airtight or watertight). In some embodiments, the sealant is an adhesive. In some embodiments, the sealant is an organic sealant (e.g. polymer sealant).

In some embodiments, the substrate comprises an aluminum alloy. In some embodiments, the substrate comprises an aluminum alloy selected from the following series: AA1XXX, AA 2XXX, AA3XXX, AA5XXX, 6XXX, or 7XXX. In an embodiment where one or more components of the shot shell casing are drawn and ironed, the component comprises an aluminum alloy selected from the group consisting of: a 7XXX series alloy, a 6XXX series alloy, a 5XXX series alloy, a 3XXX series alloy, a 2XXX series alloy, a 1XXX series alloy, or combinations thereof.

As used herein, “coating” means: a covering that is applied to the surface of an object.

As used herein, “projectile” means: the object(s) shot from the fired shot shell case. In some embodiments, the projectile is a slug. In some embodiments, the projectile is a plurality of shot. In some embodiments, the projectile is made of metal and/or metal alloys.

As used herein, “wad” means: the component that separates the projectile (e.g. shot or slug) from the charge (e.g. powder) and holds the shot together as it travels through the barrel (i.e. promotes acceleration of the projectile by preventing the combustion gases from blowing around the shot). As non-limiting examples, the wad is made of plastic, felt, or paper.

As used herein, “powder” (sometimes called charge or propellant) means: the chemical compound which burns and forms gases which push the projectile out of the barrel of the firearm.

As used herein, “primer” means: the chemicals and structure (e.g. metallic structure) that when contacted by the firing pin, explode and ignite the powder.

As used herein, “primer cup” means the component that retains the primer within the shot shell.

As used herein, “drawn and ironed” means: a process primarily used to manufacture a thin-walled tubular object (e.g. in some embodiments, the tubular object includes a closed end). In some embodiments, with this process, an appropriately sized circular disk is drawn into a cup to approximately the finished diameter of the component (e.g. casing, base assembly, cap). In some embodiments, the sidewall height of the component (e.g. casing, base assembly, or cap) is created by forcing the cup through a series of rings, thus ironing the metal thinner than the thickness of the starting material.

Various ones of the inventive aspects noted hereinabove may be combined to yield aluminum shot shells, methods of making, methods of using, and methods of recycling the same.

These and other aspects, advantages, and novel features of the invention are set forth in part in the description that follows and will become apparent to those skilled in the art upon examination of the following description and figures, or may be learned by practicing the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1C depict a shot shell and the subcomponents thereof, in accordance with the embodiments of the instant disclosure. FIG. 1A depicts a base assembly as one integral, folded piece.

FIGS. 2A-2C depicts another embodiment of a shot shell in accordance with the instant disclosure. FIG. 2A depicts the formed base assembly, which includes the upper portion and lower portion (e.g. crimped and/or adhered together with a sealant). The upper portion is configured to case the inner powder chamber (e.g. head wad), while the lower portion is configured to form the head (of the case) when the upper and lower portions are attached. FIG. 2B depicts a cut-away side view of the shot shell, depicting the mating edge and the rim of the case cooperating to form the shell rim. FIG. 2C depicts the formed integral case sleeve (e.g. with integrally scored mouth for accurate release). Referring to FIGS. 2A and 2B, the floatation device depicted in the head end (e.g. within the base assembly) is configured for buoyancy in water (e.g. promoting/facilitating case retrieval and recycling). FIG. 2D is a close up cut away partial view of the shell rim, depicting the cooperating configuration of the mating edge of the base assembly and the circumferential rim of the case.

FIGS. 3A-3C depict a method of assembly (and loading) the shot shell of FIGS. 1A-1C and 2A-2C, depicting the casing being loaded and assembled with the mouth (mouth end) facing in a downward direction.

FIGS. 4A-4D depict various embodiments for shell rims, in accordance with the instant disclosure. For example, a straight piece of metal with a flap configured two different ways to fold underneath a portion of the casing, to provide either a vertical seam or a horizontal seam to the shell rim. It is noted that the plug/spacer depicted the base assembly is an optional component (e.g. plug or spacer is removable).

FIG. 5A-C depict two alternative cap configurations. FIG. 5A depicts the snap on cap of 5B placed on the case. FIG. 5C depicts an alternative push-on style cap.

FIG. 6A-B depict an alternative embodiment in accordance with the instant disclosure, in which the formed, integral case and base assembly (with open mouth) is configured with a head wad, primer, and primer cup. As one non-limiting example, the embodiment of FIG. 6A is formed from a flat-bottomed cup which also forms both the base assembly and the case. After formation, the base assembly is pierced in the center with a flanged hole (e.g. integral, flanged hole) for primer. In this embodiment, the mouth trimmed and rolled to contain a cap (e.g. wax, plastic or metal) at upper opening/mouth.

FIGS. 7A-7D depict two different mouth scoring patterns (radial mouth—left and circumferential mouth—right) and projected openings of the mouth upon the firing event (where the firing event is depicted by the arrow). The scored mouth feature promotes the cap or upper end of the case to open in a particular pattern upon a firing event.

FIG. 8A-D depicts top plan views of four different embodiments of scoring patterns (for the cap or mouth end of the case), as labeled in the corresponding Figure legend.

FIG. 9A-B depict a cut away side view of a score pattern, depicting the depth of the score varies across the distance of the mouth end.

FIGS. 10A-10H depicts multiple embodiments depicting various configurations of the mouth end,

FIG. 10A depicts a flat/planar mouth end.

FIG. 10B depicts a concave mouth end with an angled perimetrical rim configured around the upper surface of the mouth end (between the recessed central planar portion and the perimetrical edge of the case.

FIG. 10C depicts a concave mouth end with a stepped perimetrical rim configured around the upper surface of the mouth end (between the recessed central planar portion and the perimetrical edge of the case.

FIG. 10D depicts a concave mouth end with a perimetrical rim configured around the upper surface of the mouth end (between the rounded (angled/arcuate), recessed central portion and the perimetrical edge of the case.

FIG. 10E depicts a convex (rounded) mouth end, configured with a rounded top extending outward/upward from the perimetrical sidewall of the casing.

FIG. 10F depicts an extended mouth end, where the sidewall of the casing comprises a perimetrical bevel between the mouth end and the sidewall.

FIG. 10G depicts an extended mouth end, where the sidewall of the casing comprises a perimetrical collar (i.e. with a smaller diameter than that of the sidewall of the casing), the collar positioned between the mouth end and the sidewall.

FIG. 10H is similar to that depicted in FIG. 10G, with FIG. 10H depicting an elongated/extended collar portion (i.e. longer than that depicted in FIG. 10G).

FIGS. 11A-11C depicts three different embodiments of shell cases in accordance with various embodiments of the instant disclosure. FIG. 11A depicts a case that is impact extruded with a cap configured to fit on the mouth end. FIG. 11B depicts a case that is drawn and ironed, with a base assembly. FIG. 11C depicts a case having a base assembly thereon, which is drawn and ironed, with a cap configured to fit onto the mouth end.

FIGS. 12A-12C depicts three different embodiments of shell cases in accordance with various embodiments of the instant disclosure. FIG. 12A depicts a case that is impact extruded with a scored cap configured to fit on the mouth end. FIG. 12B depicts a case that is drawn and ironed, with a base assembly and having a scored mouth end. FIG. 12C depicts a case having a base assembly thereon, which is drawn and ironed, with a scored cap configured to fit onto the mouth end.

DETAILED DESCRIPTION

Reference will now be made in detail to the accompanying drawings, which at least assist in illustrating various pertinent embodiments of the present invention.

FIGS. 1A-1C depict a shot shell 10 and the subcomponents thereof, in accordance with the embodiments of the instant disclosure. FIG. 1A depicts a base assembly 30 as one integral, folded piece.

FIGS. 2A-2C depicts another embodiment of a shot shell 10 in accordance with the instant disclosure. FIG. 2A depicts the formed base assembly 30, which includes the upper portion 72 and lower portion 74 (e.g. sealed via a forming seal 18, including a crimp 66 and/or adhering substance 64 together with a sealant 34). The upper portion 72 is configured to case/encase the inner powder chamber 68 (e.g. head wad 70), while the lower portion 74 is configured to form the head 44 (of the case 20) when the base assembly 30 and case 20 are attached. FIG. 2B depicts a cut-away side view of the shot shell 10, depicting the mating edge 36 and the rim 26 of the case 20 configured to cooperate and form the shell rim 40, where the shell rim 40 is configured with a circumferential edge/raised portion. FIG. 2C depicts the formed integral case sleeve 20 (e.g. with integrally scored 46 mouth end 22 for accurate release). Referring to FIGS. 2A and 2B, the floatation device/buoy 62 depicted in the head end (e.g. within the base assembly 30) is configured for buoyancy in water (e.g. promoting/facilitating case retrieval and recycling). FIG. 2D is a close up cut away partial view of the shell rim 26, depicting the cooperating configuration of the mating edge 36 of the base assembly 30 and the circumferential rim 26 of the case 20.

FIGS. 3A-3C depict a method of assembly (and loading) the shot shell 10 of FIGS. 1A-1C and 2A-2C, depicting the casing 20 being loaded and assembled with the mouth (mouth end 22) facing in a downward direction.

FIGS. 4A-4D depict various embodiments for shell rims 26, in accordance with the instant disclosure. For example, a straight piece of metal with a flap configured two different ways to fold underneath a portion of the casing 20, to provide either a vertical seam or a horizontal seam to the shell rim 40. It is noted that the plug/spacer depicted the base assembly 30 is an optional component (e.g. plug or spacer is removable).

FIG. 5A-C depict two alternative cap configurations. FIG. 5A depicts the snap-on cap 24 (e.g. lid) of 5B placed on the case 20. FIG. 5C depicts an alternative push-on style cap 24.

FIG. 6A-B depict an alternative embodiment in accordance with the instant disclosure, in which the formed, integral case 20 and base assembly 30 (with open mouth 22) is configured with a head wad 14, primer 18, and primer cup 32. As one non-limiting example, the embodiment of FIG. 6A is formed from a flat-bottomed cup which also forms both the base assembly 30 and the case 20. After formation, the base assembly 30 is pierced in the center with a flanged hole (e.g. integral, flanged hole) for the primer 18. In this embodiment, the mouth 22 is trimmed and rolled to configure the mouth to contain a cap 24 (e.g. wax, plastic or metal) at upper opening/mouth 22.

FIGS. 7A-7D depict two different mouth 22 scoring patterns 48 (radial mouth—left and circumferential mouth—right) and projected openings of the mouth 22 upon the firing event (where the firing event is depicted by the arrow). The scored 46 mouth 22 feature promotes the cap 20 or upper end of the case 20 to open in a particular pattern upon a firing event.

FIG. 8A-D depicts top plan views of four different embodiments of scoring patterns 48 (for the cap 24 or mouth end 22 of the case 20), as labeled in the corresponding Figure legend: radial, scroll, circumferential and radial, and cross-hatched.

FIG. 9A-B depict a cut away side view of a score pattern 48, depicting the depth of the score 46 (e.g. residual thickness) varies across the distance of the mouth end 22.

FIGS. 10A-10H depicts multiple embodiments depicting various configurations of the mouth end 22.

FIG. 10A depicts a flat/planar mouth end 22.

FIG. 10B depicts a concave mouth end 22 with an angled perimetrical rim 40 configured around the upper surface of the mouth end 22 (between the recessed central planar portion and the perimetrical edge of the case 20.

FIG. 10C depicts a concave mouth end 22 with a stepped perimetrical rim configured around the upper surface of the mouth end 22 (between the recessed central planar portion and the perimetrical edge of the case.

FIG. 10D depicts a concave mouth end 22 with a perimetrical rim configured around the upper surface of the mouth end 22 (i.e. between the rounded (e.g. angled/arcuate), recessed central portion and the perimetrical edge of the case 20).

FIG. 10E depicts a convex (rounded) mouth end 22, configured with a rounded top extending outward/upward from the perimetrical sidewall of the casing 20.

FIG. 10F depicts an extended mouth end, where the sidewall of the casing 20 comprises a perimetrical bevel between the mouth end 22 and the sidewall 28.

FIG. 10G depicts an extended mouth end 22, where the sidewall of the casing 20 comprises a perimetrical collar (i.e. with a smaller diameter than that of the sidewall of the casing), the collar positioned between the mouth end and the sidewall.

FIG. 10H is similar to that depicted in FIG. 10G, with FIG. 10H depicting an elongated/extended collar portion (i.e. longer than that depicted in FIG. 10G).

FIGS. 11A-11C depicts three different embodiments of shell cases in accordance with various embodiments of the instant disclosure. FIG. 11A depicts a case that is impact extruded with a cap 24 configured to fit on the mouth end 22. FIG. 11B depicts a case 20 that is drawn and ironed, with a base assembly 30. FIG. 11C depicts a case 20 having a base assembly 30 thereon, which is drawn and ironed, with a cap 24 configured to fit onto the mouth end 22.

FIGS. 12A-12C depicts three different embodiments of shell cases 10 in accordance with various embodiments of the instant disclosure. FIG. 12A depicts a case that is impact extruded with a scored 46 cap 24 configured to fit on the mouth end 22. FIG. 12B depicts a case that is drawn and ironed, with a base assembly and having a scored mouth end 22. FIG. 12C depicts a case 20 having a base assembly 30 thereon, which is drawn and ironed, with a scored 46 cap 24 configured to fit onto the mouth end 22.

In one aspect, a shell case, is provided, comprising: a base assembly configured with an upper portion and a lower portion, wherein the lower portion is configured to hold a primer cup; wherein the upper portion is configured to retain the charge/powder, and a sidewall configured to perimetrically extend between the lower portion and upper portion; wherein the sidewall is constructed with a mating edge which extends generally outward from the sidewall adjacent to the lower end; and a case, the case comprising a mouth end an open end (generally opposed from the mouth end) and a sidewall configured to perimetrically surround the mouth end and extend from the mouth end towards the open end to define an opening therein, wherein the case is configured with a perimetrical rim (e.g. lip, collar) adjacent to and configured to extend around the opening; wherein the mating edge is configured to cooperate with the rim of the case to create a rim having a perimetrical seal adjacent to a head end of the shell case.

In one aspect, a shot shell case is provided, comprising: a case, the case comprising a head end an open end (generally opposed from the head end) and a sidewall configured to perimetrically surround the head end and extend from the head end towards the open end to define an opening therein, wherein the case is configured with a perimetrical rim (e.g. lip, collar) adjacent to and configured to extend around the opening; wherein the head end is configured to with a circumferential rim adjacent to the sidewall, wherein the head end is configured to retain the charge and the primer; and a cap configured to fit onto the open end, wherein the cap is configured with a retention feature designed to secure onto the open end.

In some embodiments, the upper portion and lower portion of the base assembly are integrally formed (unitary piece).

In some embodiments, the upper portion and lower portion of the base assembly are attached (e.g. via mechanical attachment (e.g. crimping), welding, or adhering (e.g. glue, sealant).

In some embodiments, at least one of the base assembly and the case are constructed from a sheet of an aluminum alloy.

In some embodiments, at least a portion of the shot shell comprises a surface feature (e.g. additive) to the aluminum material.

In some embodiments, the shot shell comprises a drawn and ironed component.

In some embodiments, the shot shell comprises an impact extruded component.

In some embodiments, the shot shell comprises a spun formed component.

In some embodiments, the shot shell comprises a machined component.

In some embodiments, the base assembly comprises a drawn and ironed component.

In some embodiments, the base assembly comprises an impact extruded component.

In some embodiments, the base assembly is stamp formed.

In some embodiments, the base assembly comprises a spun formed component.

In some embodiments, the base assembly comprises a machined component.

In some embodiments, the cap comprises a drawn and ironed component.

In some embodiments, the cap comprises an impact extruded component.

In some embodiments, the cap is stamp formed.

In some embodiments, the cap comprises a spun formed component.

In some embodiments, the cap comprises a machined component.

In some embodiments, the surface feature provides a coefficient of friction not greater than 0.25.

In some embodiments, the surface feature provides a reduction to the coefficient of friction between the aluminum shot shell and the barrel of the firearm to an amount of less than 0.45 (i.e. the coefficient of friction between aluminum and steel). In some embodiments, in order to reduce, prevent, and/or eliminate galling and/or sticking of the case in the gun chamber, the coefficient of friction between the aluminum shell and the gun chamber is reduced via the surface feature to less than 0.45.

In some embodiments, the surface feature is configured to provide a coefficient of friction of at least 0.1 to not greater than 0.3.

In some embodiments, the surface feature provides a coefficient of friction not greater than 0.25.

In some embodiments, the surface feature is configured to provide coefficient of friction of at least 0.1; at least 0.15; at least 0.2; at least 0.25; or at least 0.3.

In some embodiments, the surface features is configured to provide a coefficient of friction of not greater than 0.1; not greater than 0.15; not greater than 0.2; not greater than 0.25; or not greater than 0.3.

In some embodiments, the surface feature provides a reduction to the coefficient of friction between the aluminum shot shell and the chamber of the firearm of at least 25% to not greater than 80%.

In some embodiments, the surface feature provides a reduction in the coefficient of friction of: at least 25%; at least 30%; at least 35%; at least 40%; at least 45%; at least 50%; at least 55%; at least 60%; at least 65%; at least 70%; at least 75%; or at least 80%.

In some embodiments, the surface feature provides a reduction in the coefficient of friction of: not greater than 25%; not greater than 30%; not greater than 35%; not greater than 40%; not greater than 45%; not greater than 50%; not greater than 55%; not greater than 60%; not greater than 65%; not greater than 70%; not greater than 75%; or not greater than 80%.

In some embodiments, the surface feature provides a reduction to the coefficient of friction between the aluminum shot shell and the chamber of the firearm of up to 80%.

In some embodiments; the surface feature provides a reduction to the coefficient of friction between the aluminum shot shell and the chamber of the firearm of at least 25%.

In some embodiments, the surface features comprises a paint.

In some embodiments, the surface feature comprises an embossed design (e.g. hologram).

In some embodiments, the surface feature comprises an embossed design with a lacquer overcoat.

In some embodiments, the surface feature comprises a printed component (e.g. aluminum packaging printing technology).

In some embodiments, the surface feature comprises a grooved surface (e.g. raised ridges interspaced with valleys).

In some embodiments, the grooved surface is aligned such that the grooves run parallel to the central axis of the shot shell.

In some embodiments, the surface feature comprises a coating.

In some embodiments, the coating comprises an organic conformal coating material (e.g. flouropolymer).

In some embodiments, the coating comprises an inorganic conformal coating material (e.g. silicone based material).

In some embodiments, the coating comprises an anodic coating (e.g. Type II, Type III hard anodized coating),

In some embodiments, the coating comprises an additive (e.g. ceramic additive).

In some embodiments, the additive comprises: alumina, titania, zirconia, boron nitride (e.g. hexagonal boron nitride, cubic boron nitride, other polymorphs), and combinations thereof.

In some embodiments, the surface feature is applied to the surface of the case via rolling; spraying; brushing; printing; dipping; powder coating; coating; EDM of surface, plasma coating, and combinations thereof.

In some embodiments, the base assembly is configured with floatation devices which provide buoyancy to the fired case in a liquid environment.

In some embodiments, the floatation device is configured via a void space in the base assembly, which is configured with a sealant to be air and/or water tight.

In some embodiments, the mouth end of the case is configured with a score pattern.

In some embodiments, the cap is configured with a score pattern.

In some embodiments, the cap is configured with a retention feature (e.g. configured to secure the cap onto the mouth end of the case and hold the cap in place).

In some embodiments, the score pattern comprises: a radial score pattern; a scroll score pattern; a circumferential score pattern; a cross-hatched (pie-shaped) score pattern; an x-configuration score pattern, and a circumferential & radial score pattern.

In some embodiments, the score pattern comprises a score residual (e.g. the thickness of the metal left below the score line).

In some embodiments, the score residual is at least 0.001″ to not greater than 0.015″ (e.g. based upon sheet thickness).

In some embodiments, the score residual is: at least 0.001″; at least 0.003″; at least 0.005″; at least 0.010″; at least 0.013″, or at least 0.016″.

In some embodiments, the score residual is: not greater than 0.002″; not greater than 0.004″; not greater than 0.006″; not greater than 0.010″; not greater than 0.014″, or not greater than 0.016″.

In some embodiments, the case is configured with a score mouth around the mouth end of the case.

In some embodiments, the score pattern is configured to eject the entire mouth (opened end of the case via firing event) with retention device (closure feature).

In some embodiments, the score pattern is configured to provide a spread in correlation to the score pattern (e.g. controlled to narrow or wide spread of shot via the score pattern and/or score mouth characteristics).

In some embodiments, the score pattern is configured to retain the mouth (opened end of the case via firing event) with retention device (closure feature).

In some embodiments, the score pattern provides a constant depth.

In some embodiments, the score pattern has varied depths (differing depths at different positions along the score pattern (e.g. may be designed to promote a particular performance of reproducibility of shot pattern).

In some embodiments, the thickness of the case is from at least 0.005″ to not greater than 0.015″.

In some embodiments, a sealant is applied to at least a portion of the base assembly.

In some embodiments, a sealant is applied to at least a portion of the head end of the shot shell.

In some embodiments, the method comprises scoring the mouth end of the case (e.g. cap or top surface).

In some embodiments, scoring is completed with a score knife and anvil.

In some embodiments, the method comprises scoring the mouth end of the case (e.g. cap or top surface).

In some embodiments, the drawn & ironed case of the instant method(s) have a uniform thickness when compared at the head end vs. the mouth end.

In some embodiments, the impact extruded case component(s) of the instant method(s) have a non-uniform thickness when compared at the head end vs. the mouth end.

In some embodiments, the cap is configured to mechanically attach to the mouth end of the case.

In some embodiments, the cap is configured to snap onto the mouth end (upper opening) of the case.

In some embodiments, the cap is configured to crimp onto the end (upper opening) of the case.

In some embodiments, the cap is configured to screw onto the end (upper opening) of the case.

In some embodiments, the cap is welded onto the mouth end (upper opening) of the case.

In some embodiments, the cap is adhered onto the mouth end (upper opening) of the case.

In some embodiments, the cap is sealed onto the mouth end (upper opening) of the case.

In some embodiments, the cap is removably attached to the mouth end (upper opening) of the case (e.g. pop-off, screw off, etc).

In some embodiments, the shot shell rim comprises an angle of at least 55° to not greater than 90.

In one aspect, a method of making a shot shell is provided, comprising: drawing an aluminum alloy sheet into a cup; ironing the sidewall of the cup to bring the case to the desired height; piercing a center of a mouth end portion of the cup; bending the metal up to form a recessed portion configured to retain the primer cup; removing a center portion when the forming is complete.

In some embodiments, the method further comprises trimming the formed component.

In some embodiments, the method further comprises forming the rim (or mating edge) at the bottom of the component (case, base assembly, or cap).

In some embodiments, performing a partial redraw to further refine the cup shape.

In some embodiments, the method comprises: cleaning the shot shell (to remove dirt and lubricant); and applying a surface feature to the case.

In some embodiments, the method comprises spinning (rotary spinning) the cap over the case to assemble the shot shell.

In some embodiments, the shot shell comprises a plurality of drawn and ironed components, including: a cylindrical case having a mouth end portion a perimetrical sidewall extending up from the mouth end portion with an open end opposed from the mouth end portion; a base assembly comprising an upper portion configured with a recessed portion and a lower portion configured to house a primer.

While various embodiments of the present invention have been described in detail, it is apparent that modifications and adaptations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and adaptations are within the spirit and scope of the present invention.

REFERENCE NUMBERS

-   shot shell 10 -   case 20 -   mouth end 22 -   cap 24 -   rim (of case) 26 -   sidewall of ease 28 -   base assembly 30 -   upper portion (of base assembly) 72 -   lower portion (of base assembly) 74 -   primer cup 32 -   sealant 34 -   mating edge (of base assembly) 36 -   shell rim (with a circumferential edge) 40 -   base assembly end 42 -   head end 44 -   score 46 -   score pattern 48 -   surface treatment/feature 50 -   coating 52 (one embodiment of 50) -   additive to coating 54 (one embodiment of 50) -   paint 58 (one embodiment of 50) -   adherent 64 -   head wad 70 -   inner powder chamber 68 -   embossed design 56(one embodiment of 50) -   printed surface feature 58 (one embodiment of 50) -   grooved surface 60 (one embodiment of 50) -   projectile (e.g. shot/slug) 16 -   wad 14 -   powder 12 -   primer 18 -   buoy (void space in head end) 62 -   forming seal 18 (e.g. formed via mechanical manipulation of at least     one component, e.g. crimp (66), roll, seam) -   cap attachment mechanism 76 -   snap-on configuration/mechanism 78 -   nose lid 80 

What is claimed is:
 1. A shell case, comprising: a base assembly configured with an upper portion and a lower portion, wherein the lower portion is configured to hold a primer cup; wherein the upper portion is configured to retain a charge, and a sidewall configured to perimetrically extend between the lower portion and upper portion; wherein the sidewall is constructed with a mating edge which extends generally outward from the sidewall adjacent to the lower end; and a case, the case comprising a mouth end, an open end generally opposed from the mouth end, and a sidewall configured to perimetrically surround the mouth end and extend from the mouth end and extend towards the open end to define an opening therein, wherein the case is configured with a perimetrical rim adjacent to and configured to extend around the opening; wherein the mating edge of the base assembly is configured to cooperate with the perimetrical rim of the case to create a rim having a perimetrical seal adjacent to a head end of the shell case.
 2. The shot shell case of claim 1, wherein the upper portion and lower portion of the base assembly are integrally formed as a unitary piece.
 3. The shot shell case of claim 2, wherein the upper portion and lower portion of the base assembly are attached via mechanical attachment including: a forming operation, crimping, welding, or adhering with a sealant.
 4. The shot shell case of claim 1, wherein at least one of the base assembly and the case are constructed from a sheet of an aluminum alloy.
 5. The shot shell case of claim 1, wherein at least a portion of the shot shell comprises a surface feature on the aluminum material,
 6. The shot shell case of claim 5, wherein the surface feature is configured to provide a coefficient of friction not greater than 0.25.
 7. The shot shell case of claim 5, wherein the surface feature provides a reduction to the coefficient of friction between the aluminum shot shell and the barrel of the firearm to an amount of less than 0.45.
 8. The shot shell case of claim 5, wherein the surface feature comprises at least one of: a paint; an embossed design; an embossed design with a lacquer overcoat a hologram; a printed component; a grooved surface having raised ridges interspaced with valleys; or a coating.
 9. The shot shell of claim 8, wherein the surface feature comprises a coating the coating comprising an organic conformal coating material having flouropolymer therein.
 10. The shot shell of claim 8, wherein the surface feature comprises a coating, the coating comprises an anodic coating selected from a Type II or Type III hard anodized coating.
 11. The shot shell of claim 8, wherein the surface feature comprises a coating, the coating comprises a ceramic additive.
 12. The shot shell of claim 11, wherein the additive is selected from the group consisting of; alumina, titania, zirconia, boron nitride, hexagonal boron nitride, cubic boron nitride, and combinations thereof.
 13. The shot shell of claim 1, wherein the base assembly is configured with at least one floatation device.
 14. The shot shell of claim 1, wherein the mouth end of the case is configured with a score pattern.
 15. The shot shell of claim 1, further comprising a drawn and ironed component; an impact extruded component; a spun formed component; a machined component; and combinations thereof.
 16. The shot shell of claim 1, wherein the base assembly is: drawn and ironed; impact extruded; stamp formed; spun formed; machined; or combinations thereof.
 17. The shot shell of claim 14, wherein the score pattern is selected from the group consisting of: a radial score pattern; a scroll score pattern; a circumferential score pattern; a cross-hatched score pattern; an x-configuration score pattern, and a circumferential and radial score pattern.
 18. The shot shell of claim 14, wherein the score pattern comprises a score residual of at least 0.001″ to not greater than 0.015″, based upon sheet thickness.
 19. The shot shell of claim 14, wherein the case is configured with a score mouth around the mouth end of the case.
 20. The shot shell of claim 14, wherein the score pattern is configured to eject the entire mouth with retention device upon a firing event,
 21. A shot shell case, comprising: a case, the case comprising a head end an open end generally opposed from the head end and a sidewall configured to perimetrically surround the head end and extend from the head end towards the open end to define an opening therein, wherein the case is configured with a perimetrical rim having a collar adjacent to and configured to extend around the opening; wherein the head end is configured to with a circumferential rim adjacent to the sidewall, wherein the head end is configured to retain the charge and the primer; and a cap configured to fit onto the open end, wherein the cap is configured with a retention feature designed to secure onto the open end.
 22. The shot shell of claim 21, wherein the cap is drawn and ironed; impact extruded; machined; or stamp formed.
 23. The shot shell of claim 21, wherein the cap is configured with a score pattern.
 24. The shot shell of claim 21, wherein the cap is configured with a retention feature to secure the cap onto the mouth end of the case and hold the cap in place.
 25. The shot shell of claim 21, wherein the cap is configured to mechanically attach to the mouth end of the case.
 26. The shot shell of claim 21, wherein the cap is configured to snap onto the mouth end of the case.
 27. The shot shell of claim 21, wherein the cap is configured to crimp onto the end of the case.
 28. The shot shell of claim 21, wherein the cap is configured to attach to the end of the case via: a screw; a weld; glue; a forming operation including a crimp or seam; sealant; and combinations thereof.
 29. The shot shell of claim 21, wherein the cap is removably attached to the mouth end via a threaded engagement.
 30. A method comprising: drawing an aluminum alloy sheet into a cup; ironing the sidewall of the cup to bring the case to the desired height; piercing a center of a mouth end portion of the cup; bending the metal up to form a recessed portion configured to retain the primer cup; and removing a center portion when the forming is complete to provide a case configured to fit onto a shot shell.
 31. The method of claim 30, further comprising: trimming the formed component.
 32. The method of claim 30, further comprising: forming the rim and/or mating edge at the bottom of the at least one: case, base assembly, or cap.
 33. The method of claim 30, further comprising: performing a partial redraw to further refine the cup shape.
 34. The method of claim 30, further comprising: cleaning the shot shell to remove dirt and lubricant; and applying a surface feature to the case.
 35. The method of claim 30, further comprising: spinning the cap over the case to assemble the shot shell.
 36. The method of claim 30, further comprising: assembling a plurality of drawn and ironed shot shell components, including: a cylindrical case having a mouth end portion a perimetrical sidewall extending up from the mouth end portion with an open end opposed from the mouth end portion; a base assembly comprising an upper portion configured with a recessed portion; and a lower portion configured to house a primer. 